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ROTARY MOWER Powered By Docstoc
					                       ROTARY
                       MOWER
                 OPERATION, SERVICE
                & PARTS MANUAL FOR

               L-G-40-40-P, L-G-48-40-P,
              L-G-60-40-P & L-G-72-40-P
                  Slip Clutch Models:
           L-G-60-40-SC-P & L-G-72-40-SC-P

                                     February 2003

FORM: RotMwrBook.QXD
         TABLE OF CONTENTS


Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Set-up Instructions . . . . . . . . . . . . . . . . . . . . . . .2

Preparation & Training . . . . . . . . . . . . . . . . . . . .3

Operational Safety . . . . . . . . . . . . . . . . . . . . . .4-5

Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . .6

Mower Safety Decals . . . . . . . . . . . . . . . . . . . . . .7

General Maintenance . . . . . . . . . . . . . . . . . . . . .8

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .9

Mower Assembly . . . . . . . . . . . . . . . . . . . . . .10-11

Gearbox Assembly . . . . . . . . . . . . . . . . . . . .12-15

Stump Jumper Assembly . . . . . . . . . . . . . . . . .16

Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-18

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . .19


Date of Purchase:_____________________________

Model Number:_______________________________

Serial Number _______________________________
                      INTRODUCTION

We welcome you as an owner of a Gearmore mower. Please read the
following instructions and refer to them when required:

          BEFORE OPERATING YOUR MOWER

  1.   Inspect for damage and loose or missing parts. Make sure all fittings and
       drive components are secure.

  2.   Lubrication (See Lubrication Section).

  3.   Remove all large, foreign objects from area being mowed.

                     TO OPERATE MOWER

  1.   Connect mower to the tractor 3-point hitch lower link arms. (Make sure
       tractor and mower are on a level surface.)

  2.   Connect top link of tractor to mower and adjust turnbuckle so the mower
       is level with the ground.

  3.   Install driveshaft after making sure it is the correct length. (See separate
       warning sheet on the correct method of achieving the proper driveshaft
       length.)

  4.   Set height of tailwheel based on what height you want to cut. Example:
       The blades are set 1" above the skids. Thus, if you want a 2" cut, you
       would set tailwheel so skids are 1" above ground.

  NOTE:      The mower is designed to float on the tailwheel and mower
             3-point hitch, so the mower should not be dragged on the ground.

  5.   Set height stops on the tractor 3-point lift so mower will not be raised
       higher than necessary. Failure to do this could cause damage by putting
       excessive angle on the driveshaft.

  6.   Engage the tractor PTO when tractor engine is at idle speed. Engaging
       the PTO with engine at full speed will reduce the life of the driveshaft.
       For most cutting operations, a ground speed of 3 to 5 MPH and PTO at
       full 540 RPM is recommended.

                                                                              Page 1
            SET-UP INSTRUCTIONS

1.   Bolt the flat plates (ref. #1) to inside of deck ears (single notch side down).

2.   Mount the a-frame (ref. #2) to the outside of flat plates (ref. #1) using
     Cat. I pins supplied (ref. #3). (Do not tighten at this time)

3.   Remove tailwheel a-frame (ref. #4) bolts and mount the lift arm braces
     (ref. #5) using existing bolts. (Do not tighten at this time)

4.   Bend lift arm braces (ref. #5) towards a-frame (ref. #2) and bolt lift arm
     braces to outside of a-frame and floating top link (ref. #6) to a-frame.

5.   Tighten all bolts that you have loosened and installed. By using an
     impact air gun, (ref. #5) lift arm braces will fit into position.

6.   Install driveline onto gearbox input shaft using bolt and retaining clip
     supplied. Check for proper PTO shaft length.




                                                                                 Page 2
                         PREPARATION

       READ THIS BEFORE OPERATING MOWER

                                 TRAINING
Know your controls and how to stop tractor engine and mower quickly in an
emergency. READ THIS OPERATOR’S MANUAL AND THE MANUAL
PROVIDED WITH YOUR TRACTOR.

To avoid accident or injury, do not allow anyone to operate this equipment without
proper instructions. Any person who operates this equipment must be instructed in
and be capable of the safe operation of the unit, its attachments and all controls.

DO NOT allow children to operate machine, or adults to operate it without proper
instructions.


                          BEFORE OPERATION

         Always wear relatively tight and belted clothing when operating
         mower. Loose clothing should not be worn, as it could get caught in
         the moving parts or controls. Wear sturdy, rough-soled work shoes
         and protective equipment for eyes, hands, hearing and head. Never
         operate tractor or implements in bare feet, sandals or sneakers.

         Never permit any person other than the operator to ride on board the
         tractor at any time. DO NOT allow riders on mower at any time.

         Clear area of stones, branches or other debris that might be thrown,
         causing injury or damage.

         Operate only in daylight or good artificial light.

         Ensure mower is properly mounted, adjusted and in good operating
         condition.

         Ensure all PTO and other safety shielding is properly installed and in
         good condition.




                                                                                  Page 3
          OPERATIONAL SAFETY

Guards and safety shields are for your protection. DO NOT operate
equipment unless they are in place.

Read and observe all safety decals on the tractor and mower (see page7).

Always operate tractor PTO (power take-off) at recommended
RPM (revolutions per minute).

Stay away from PTO shaft and mower when
engaging PTO.

Disengage tractor PTO and shift into neutral
before attempting to start engine.

NEVER allow anyone within 25' of machine
while it is in operation.

DO NOT stop or start suddenly when going uphill
or downhill. Avoid operation on steep slopes.

Be alert for holes in terrain and other hidden hazards.
Always drive slowly over rough ground.

Reduce speed on slopes and in sharp turns to prevent
tipping or loss of control. Be careful when changing
direction on slopes.

Stop mower and tractor immediately upon striking
an obstruction. Turn off engine, inspect mower and
repair any damage before resuming operation.

Disengage power to mower and stop engine before dismounting from tractor,
before making any repairs or adjustments, transporting, or unclogging mower.

Take all possible precautions when leaving tractor unattended. Disengage
PTO, lower mower, shift into neutral, set parking brake, stop engine and
remove key from ignition.




                                                                       Page 4
                OPERATIONAL SAFETY

Continued....

      Front tractor weights or front tire ballast should be used to enhance front end
      stability on small tractors.

      NEVER operate mower in raised position.

      Check to make sure PTO is properly connected
      and that the driveline is correct to prevent
      bottoming out or pulling apart during the full
      lift range of the hitch.

      This implement is designed for a one-man operation. It is the responsibility
      of the tractor operator to see that no one is in the proximity of the implement
      when it is started. DO NOT operate the implement when another person is
      within 25' of the implement.

      NEVER put hands or feet under mower deck
      while tractor engine or mower is running.




                                                                                 Page 5
         MAINTENANCE SAFETY

Support the mower with safety stands or blocks before working beneath it.

Follow good shop practices:



A. Keep service area clean and dry.

B. Be sure electrical outlets and tools
   are properly grounded.

C. Use adequate light for the job at
   hand.



Use only tools, jacks and hoists of sufficient capacity for the job.

NEVER work on the mower unless the tractor engine is off and the
driveline is disconnected.

ALWAYS wear heavy canvas or leather gloves when handling mower
blades.

NEVER wear loose or frayed clothing when working on moving parts.
(i.e. gearbox, blade pan, driveline, etc.)

Make sure all guards are in place and properly secured when all
maintenance work is completed.




                                                                       Page 6
         MOWER SAFETY DECALS

1.   Keep all safety decals and signs clean and legible at all times.

2.   Replace safety decals and signs that are missing or have become illegible.
     (Contact Gearmore at 909.548.4848 for free replacement safety decals.)




                                                                           Page 7
              GENERAL MAINTENANCE
Carefully follow all instructions as stated in this manual. This includes operation,
lubrication, safety and maintenance. This mower was designed and built for years
of reliable service if properly cared for. However, rotary mowers are a high RPM
machine, thus daily attention is required.

          Check all bolts for tightness.

          Check to make sure all safety guards are in place.

          Check to remove any trash build-up.

          Check lubrication - see lubrication section.

          Check blades to make sure they are securely fastened.

                        SERVICING BLADES
When replacing or grinding blades, both blades must be replaced or re-ground at
the same time to maintain the proper balance in the mower. Gearmore mowers
are equipped with special heat-treated alloy steel blades. Use only Gearmore
blades, substitutes may be dangerous. NEVER try to straighten or weld blades.

                               LUBRICATION
DRIVESHAFT - The driveshaft must be lubricated before mower is put into use.
After that, grease every 8 hours of use or when required. It is also necessary, from
time to time, to untelescope the driveshaft to clean and re-grease tubing.

GEARBOX - Check gearbox oil level through square headed screw plug. Add
SAE 90 weight oil when required. Change gearbox oil after every 400 hours of use.

TAILWHEEL - Grease every 8 hours of use or when required.

TAILWHEEL PIVOT TUBE - Grease weekly or when required.

To comply with OSHA AG Guarding Standard #1928.27, the following guards and
shields must be kept in place and in good working condition:

      1. Safety chain shielding
      2. Driveshaft shields
      3. Guards over moving parts

            BE CAREFUL AND ALWAYS THINK SAFETY FIRST!

                                                                                 Page 8
                      TROUBLESHOOTING
   PROBLEM                        CAUSE                             SOLUTION
Excessive vibration   Blades are not free to swing.         Check bushings and
                                                            movements of blades.

                      Blades are out of balance.            Check blades for damage
                                                            or replace.

Unusual noise         Loose blade bolts or worn bushings.   Tighten blade bolts, check
                                                            bushings for wear and change
                                                            as needed.

                      Bent blade carrier, blades            Replace blade carrier.
                      striking deck.

                      Deck bent causing blades to hit.      Straighten deck.

                      Gearbox low of oil.                   Check seals in gearbox and fill
                                                            to proper level.

Poor cutting          Not maintaining proper PTO speed.     Check PTO with tachometer
                                                            and operate at proper RPM.

                      Improperly adjusted.                  Adjust according to Operators
                                                            Manual.

                      Forward speed too fast.               Coordinate forward speed with
                                                            blade speed.

                      Dull blades.                          Sharpen blades.

PTO turns and         Gears stripped in gearbox.            Replace or repair gearbox.
blades do not
                      Shear bolt sheared.                   Replace shear bolt.

PTO will not          Improper lubrication.                 Separate and fill female tube
telescope                                                   half full of grease.

                      PTO twisted.                          Replace twisted portion.

                      Bent PTO.                             PTO too long. Size to tractor
                                                            according to manual.

                      Shields damaged.                      Replace.

PTO twisted           Over torqued.                         Caution operator not to
                                                            ground out machine.

                      Not maintaining correct PTO speed.    Maintain proper PTO speed.

Machine streaking     Cutting too high, leaving wheel       Cut lower and slow forward
                      tracks.                               speed down.

                      Not maintaining proper RPM            Maintain proper RPM
                      speed.                                speed.


                                                                                       Page 9
MOWER ASSEMBLY




                 Page 10
              MOWER ASSEMBLY


REF#   QTY.      PART NO.   DESCRIPTION

  1     1        403390     Lift Arm L.H.
  2     1        500001     Lift Pin Cat. I (2 pack)
  3     2        360241     Lift Arm Brace L-40-48
  3     2        360231     Lift Arm Brace L-60
  3     2        360243     Lift Arm Brace L-72
  4     1        403391     Lift Arm R.H.
  5     1        360299     Top Swivel Assembly
  6     1        311028     Bushing Swivel
  7     1        184005     Gearbox Shear Pin
  7     1        184010     Gearbox Slip Clutch
  8     1        401025     A-Frame, Tailwheel
  9     1        403001     Tire & Rim
 10     1        501280     Axle Bolt Assembly
 11     1        191100     Hub & Axle Bolt Assembly
 12     1        403020     Tailwheel Fork
 13     1        147034     Shear Pin Driveline L-60/L-72
 13     1        147029     Shear Pin Driveline L-40/L-48
 13     1        147122     Slip Clutch Driveline




                                                       Page 11
SHEAR PIN GEARBOX ASSEMBLY




                             Page 12
      SHEAR PIN GEARBOX ASSEMBLY
REF#    QTY.   PART NO.   DESCRIPTION

  1       1    129005     Retainer
  2       1    40X54X7    Oil Seal
  3       3    6208       Bearing
  4       1    131045     Spacer
  5       1    129010     Housing
  6       1    185006     Pinion
  7       3    131031     Retainer Ring
  8       1    35X54X10   Oil Seal
  9       4    101117     Bolt 3/8" x 1-1/4"
 10       1    129015     Cover
 11       6    101112     Bolt 3/8" x 1"
 12      10    103110     Lockwasher 3/8"
 13       1    131030     Retainer Ring
 14       1    185010     Gear 22T
 15       1    186010     Input Shaft
 16       1    106138     Snap Ring
 17       1    6207       Bearing
 18       1    131035     Plug 1/2" - 14NPT
 19       1    131040     Plug 1/8" - 27NPT
 20       1    500101     Shear Bolt 1/2"x3-1/2" Gr. 2 (5 pk.)
 21       1    102010     Nut 1/2"
 22       1    103010     Lockwasher 1/2"
 23       1    501110     Castle Nut 1"
 24       1    124130     Gasket
 25       1    124131     Gasket




                                                         Page 13
SLIP CLUTCH GEARBOX ASSEMBLY




                           Page 14
 SLIP CLUTCH GEARBOX ASSEMBLY
REF#   QTY.   PART NO.   DESCRIPTION

  1     1     106138     Circlip
  2     1     35X54X10   Oil Seal
  3     3     129015     Cover, Front
  4     1     124130     Gasket
  5     1     131031     Circlip
  6     1     131030     Circlip
  7     3     155005     Bearing 208
  8     1     185010     Gear, Input
  9     1     186005     Input Shaft
 10     1     6207       Bearing
 11     1     129010     Housing
 12     1     185006     Output Shaft
 13     1     131045     Spacer
 14     1     40X54X7    Oil Seal
 15     1     124131     Gasket
 16     1     129005     Cover, Bottom
 17     1     501110     Castle Nut 1"
 18     1     131035     Plug 1/2" - 14NPT
 19     1     131040     Plug 1/8" - 27NPT
 20     8     101012     Bolt 3/8" x 1"




                                             Page 15
           BLADE CARRIER ASSEMBLY




 REF#          QTY.             PART NO.          DESCRIPTION

    1            2              501001            Blade Bolt Assembly (2 pk)
    2            2              190118            Blade L-40-40-P & L-48-40-P
    2            2              190124            Blade L-60-40-P
    2            2              190130            Blade L-72-40-P
    3            1              403030            Stump Jumper L-40-40-P
    3            1              403031            Stump Jumper L-48-40-P,
                                                  L-60-40-P & L-72-40-P



                IMPORTANT

When sharpening blades, grind each blade
the same amount to maintain balance.
Replace blades in pairs. Unbalanced blades
will cause excessive vibration which can
damage gearbox bearings. Vibration may
also cause structural cracks to cutter.

Sharpen both blades at the same time to
maintain balance. Follow original sharpen-
ing pattern. Do not sharpen blade to a razor
edge, but leave at least a 1/16" blunt edge. Do
not sharpen back side of blade.




                                                                            Page 16
  PTO DRIVELINE L-40 - L-48 147029




REF#   QTY.   PART NO.    DESCRIPTION

  1     1     572040351   RS collar Yoke 1-3/8" 6-Spline
  2     2     41204       Cross Kit Assembly #4
  3     1     204046851   Outer Tube Yoke #4
  4     1     341038000   Roll Pin O.T. #4
  5     1     225101200   Outer Drive Tube #4
  6     1     225121200   Inner Drive Tube #4
  7     1     341048000   Roll Pin I.T. #4
  8     1     204046852   Inner Tube Yoke #4
  9     2     403000001   Quick Disconnect Pin Kit
 10     2     211015363   RS Collar 5-6
 11     1     211044955   Yoke 1-3/8" Round Bore
        1     5F04120F6   B & P Shield Kit With Bearings
        1     255040006   B & P Shield Bearing Inner
        1     255040005   B & P Shield Bearing Outer
        1     36728       Eurocardan Shield Kit
        1     35069       Eurocardan Bearing Inner
        1     35066       Eurocardan Bearing Outer




                                                   Page 17
 PTO DRIVELINE L-60 - L-72 147034




REF#   QTY.   PART NO.    DESCRIPTION

  1     1     572050351   RS Collar Yoke 1-3/8" 6-Spline
  2     2     41205       Cross Kit Assembly #5
  3     1     204056860   Outer Tube Yoke #5
  4     1     341053000   Roll Pin O.T. #5
  5     1     225701200   Outer Drive Tube #5
  6     1     225111200   Inner Drive Tube #5
  7     1     341002000   Roll Pin I.T. #5
  8     1     204056861   Inner Tube Yoke #5
  9     2     403000001   Quick Disconnect Pin Kit
 10     2     240003051   RS Collar 5-6
 11     1     211054954   Yoke 1-3/8" Round Bore
 12     1     572050361   RS Collar Yoke 1-3/8" 6-Spline
        1     5F05086FF   B & P Shield Kit With Bearings
        1     255050006   B & P Shield Bearing Inner
        1     255050005   B & P Shield Bearing Outer
        1     36515       Eurocardan Shield Kit
        1     36521       Eurocardan Bearing Inner
        1     36519       Eurocardan Bearing Outer




                                                   Page 18
                     LIMITED WARRANTY


GEARMORE, INC., warrants each new Gearmore product to be free from defects in materi-
al and workmanship for a period of twelve (12) months from date of purchase to the original
purchaser. This warranty shall not apply to implements or parts that have been subject to
misuse, negligence, accident, or that have been altered in any way.

Our obligation shall be limited to repairing or replacement of any part, provided that such
part is returned within thirty (30) days from date of failure to Gearmore through the dealer
from whom the purchase was made, transportation charges prepaid.

This warranty shall not be interpreted to render us liable for injury or damages of any kind or
nature, direct, consequential or contingent, to person or property. This warranty does not
extend to loss of crops, loss because of delay in harvesting or any other expenses, for any
other reasons.

Gearmore in no way warranties engines, tires, or other trade accessories, since these items
are warranted separately by these respective manufacturers.

Gearmore reserves the right to make improvements in design or changes in specification at
any time, without incurring any obligations to owners or units previously sold.

                                                                      GEARMORE, INC.
                                                                     13477 Benson Ave.
                                                                       Chino, CA 91710
Always refer to and heed machine operating warning decals on machine.




    The serial number of this product is stored in our computer database, thus
             submitting a warranty registration card is not required.




                                                                                          Page 19

				
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